Honeywell 7800 series Operating instructions

Honeywell
Brand
Honeywell
Model
7800 series
Type
Operating instructions

This manual is also suitable for

INSTALLATION INSTRUCTIONS
32-00214-01
SIL3
Capable
RM7888A
7800 SERIES Relay Module
APPLICATION
The Honeywell RM7888A Relay Module is a
microprocessor based, integrated burner control for
industrial process semiautomatically fired gas, oil, coal, or
combination fuels for single and multiple burner
industrial applications. The RM7888A requires a Relay
Module, Subbase and Amplifier for operation. Options
include Keyboard Display Module, DATA CONTROLBUS
MODULE™, Modbus™ Module, and Remote Display
Mounting.
The RM7888 intended use is in conjunction with a master
system control. The master system control determines the
purge timing and confirms air supply and air flow. The
RM7888A is programmed to provide a level of safety,
functional capability and features beyond the capability of
conventional controls. The basic functions of the RM7888
include automatic burner startup sequencing, five user
selectable operating (run) sequences, four line voltage
sequence control inputs (commonly controlled with a
Programmable Logic Controller [PLC)], flame supervision,
system status indication, system or self-diagnostics and
troubleshooting.
This document covers the following 7800 Series Relay
Modules:
RM7888A1019
RM7888A1027
RM7888A2019
RM7888A2027
Contents
Specifications ............................................................................... 2
Ordering Information ................................................................ 2
Principal Technical Features .................................................. 9
Saftey Provisons .......................................................................... 10
Installation ..................................................................................... 11
Wiring ............................................................................................... 13
Assembly ......................................................................................... 15
Operation ........................................................................................ 19
Static Checkout ............................................................................ 30
Checkout ......................................................................................... 32
Troubleshooting ........................................................................... 38
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 2
FEATURES
• Safety features:
— Closed loop logic test.
—Dynamic input check.
— Dynamic safety relay test.
— Dynamic self-check logic.
— Expanded safe-start check.
— Internal hardware status monitoring.
— Tamper resistant timing and logic.
• Access for external electrical voltage checks.
• Application flexibility.
• Communication interface capability using Modbus.
• First-out annunciation and system diagnostics are
provided by the optional Keyboard Display Module.
• Five sequence information LEDs.
• Interchangeable plug-in flame amplifiers.
• Local or remote annunciation of RM7888A operation
and fault information.
• Dependable, long-term operation provided by
microcomputer technology.
• Nonvolatile memory for retaining history files and
sequencing status after loss of power.
• Remote reset capability (optional).
• Burner controller data:
— Sequence status.
— Sequence time.
—Hold status.
—Lockout/alarm status.
— Flame signal strength.
— Expanded annunciator status.
— Total hours of operation.
— Total cycles of operation.
— Fault history of six most recent faults:
• Cycles of operation at the time of the fault.
• Expanded annunciator data at the time of the
fault.
• Fault message and code.
• Hours of operation at the time of the fault.
• Sequence status at the time of the fault.
• Sequence time at the time of the fault.
— Diagnostic information:
• Device type.
• Flame amplifier type.
• Flame failure response time.
• Manufacturing code.
• On/Off status of all line voltage digital inputs.
• Software revision and version of RM7888A via
S7800 Keyboard Display Module.
• Status of configuration jumpers.
SPECIFICATIONS
Electrical Ratings (see Table 1):
Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz
(±10%).
Keyboard Display Module: 13.0 Vdc peak full wave recti-
fied (+20/-15%).
Power Dissipation:
RM7888A: 10W maximum.
Display Module: 3W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: Total Connected Load: 20A maximum, type FRN or
equivalent.
Environmental Ratings:
Ambient Temperature:
Operating: -40° F to +140° F [-40° C to +60° C].
Storage: -40° F to + 150° F [-40° C to +66° C].
Humidity: 85% relative humidity continuous, noncon-
densing.
Vibration: 0.5G environment.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System using Dynamic self check or amplicheck ampli-
fiers with the appropriate flame detector. See form
number 65-0312 for Certificate Agreement.
Dimensions: See Fig. 1
Weight:
RM7888A: 1 pound, 10 ounces [737 grams], unpacked.
Keyboard Display Module: 4 ounces [113 grams],
unpacked.
Approvals:
Underwriters Laboratories Inc. Listed: File No. MP268,
Vol. 30. UL 37260730-2-5 / CSA C22.2 No. 60730-
2-5.
Factory Mutual Approved: Report No. 1V9A0.AF.
Swiss Re (formerly Industrial Risk Insurers): Acceptable.
Federal Communications Commission: Part 15, Class
B, Emissions.
Exida: IEC 61508:2010 Parts 1-7, SIL 3 capable.
EAC Russia
RM7888A 7800 SERIES RELAY MODULE
332-00214—01
Fig. 1. Mounting dimensions of the RM7888A Relay Module and Q7800A Subbase in in. [mm].
NOTE: The RM7888 is a component of a larger overall
combustion safety system for industrial-burner
applications. Due to the custom design nature
inherent in industrial-burner control systems, the
system designer/ integrator has responsibility for
the overall combustion system safety and system
approval. Separate appliance or site approval may
also be required. The RM7888 serves as a system
component that provides control and flame
safety monitoring for an individual burner.
Mounting:
Q7800A1005 for panel mount or Q7800B1003 or B1011
for wall or burner mount.
Accessories:
Required for Operation:
Plug-in Flame Signal Amplifier (see Table 4).
This document provides installation and static checkout
instructions. Other applicable publications are:
M15518B
BURNER CONTROL
POWER
PILOT
FLAME
MAIN
ALARM
RESET
5
(127)
5 (127)
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
5-1/4 (133)
1
6-3/32 (155)
MODULE WITH SUBBASE
Part numbers Accessories
S7810M1003 Modbus Module (optional)
S7810A1009 DATA CONTROLBUS MODULE™
(optional)
123514A Flame Simulators Rectifying
203659 Flame Simulators Ultraviolet
S7800A1001 Keyboard Display Module
S7820A1007 Remote Reset Module
203765,
205321B,
204718B
Remote Display Mounting Brackets
221818A Extension Cable Assembly 60 inch
221818C Extension Cable Assembly 120 inch
A7800A1010 Tester
Form
Number Description
63-2278 Q7700A Network Interface Unit Product Data
65-0084 Q7800A,B 22-Terminal Wiring Subbase Product
Data
65-0090 S7800A Keyboard Display Module Product Data.
65-0091 S7810A Data ControlBus Module™ Product Data
65-0095 S7820 Remote Reset Module Product Data
65-0097 221729C Dust Cover Packing Sheet
65-0101 S7830 Expanded Annunciator Product Data
65-0109 R7824, R7847, R7848, R7849, R7851, R7861,
R7886 Flame Amplifiers for the 7800 SERIES
Product Data
65-0131 221818A Extension Cable Assembly Product Data
65-0229 7800 SERIES RELAY MODULES Checkout and
Test
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 4
1The RM7888 must have an earth ground providing a connection between the subbase and the control panel or the
burner. The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse (or breaker) in
event of an internal short circuit. The RM7888 needs a low impedance ground connection to the equipment frame
which, in turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF fre-
quencies, the connection must be made with minimum length conductors having maximum surface areas. Wide straps
or brackets are preferred rather than leadwires. Be careful to make sure that mechanically tightened joints along the
ground path, such as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coat-
ings and are protected against mating surface corrosion.
22000 VA maximum connected load to RM7888A Assembly.
3See Table 2 and 3 for load combinations.
IMPORTANT
A Flame Detection System that must be ordered separately is required for operation. To select your Plugin Flame
Signal Amplifier and applicable Flame Detector, see Table 4.
Table 2. Combinations for Terminals 8, 9, and 10.
aJumper Terminals 8 to 9 for direct spark ignition.
Table 1. Terminal Ratings.
Terminal Number Description Ratings
GFlame Sensor Ground160 to 220 Vac, current limited.
Earth G Earth Ground1—
L2(N) Line Voltage Common —
3 Alarm 120 Vac, 1A pilot duty.
4 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (±10%)2
5 Air Valve 120 Vac, 9.8A FL, 58.8A LR (inrush).
6 Special Function 1 120 Vac, 1 mA.
7 Limits Complete 120 Vac, 9A.
8 Pilot Valve 3
9Main Fuel Valve
3
10 Ignition 3
F(11) Flame Sensor 60 to 220 Vac, current limited.
12(B) Firing Rate High Fire 120 Vac, 75 VA Pilot Duty.
13(R) Firing Rate Common 120 Vac, 75 VA Pilot Duty.
14(W) Firing Rate Low Fire 120 Vac, 75 VA Pilot Duty.
15 Firing Rate Modulate 120 Vac, 75 VA Pilot Duty.
16 Unused —
17 Special Function 2 120 Vac, 1 mA.
18 @Low Fire Input 120 Vac, 1 mA.
19 Special Function 3 120 Vac, 1 mA.
20 Special Function 4 120 Vac, 1 mA.
21 Flame Proven 120 Vac, 2A pilot duty.
22 Shutter 120 Vac, 0.5A.
Pilot Fuel 8 Main 9 Ignition 10
CFNo Load
BFNo Load
FFA
No Load F A
DFaA
DDA
No Load DaA
RM7888A 7800 SERIES RELAY MODULE
532-00214—01
Table 3. Composition of Each Combination.
ABCDF
4.5A ignition 50 VA Pilot Duty plus
4.5A ignition
180 VA Ignition plus
Motor Valves with:
660 VA inrush,
360 VA open,
250 VA hold.
2A Pilot Duty 65 VA Pilot Duty plus
motor valves with:
3850 VA inrush,
700 VA open,
250 VA hold.
Table 4. Flame Detection Systems (FIGS. 2–8).
Plug-In Flame Signal Amplifiers Applicable Flame Detectors
Type Color
Self-
Checking Model
Flame
Failure
Response
Time (sec)aFuel Type Models
Rectification Green No R7847Ae0.8 or 3 Gas Rectifying
Flame Rod
Holdersh
C7004,
C7007,
C7011
Complete
Assemblies:
C7008,
C7009, Q179
No R7847Ae3 Gas, oil, coal Ultraviolet
(Purple
Peeper)
C7012A,C
Dynamic
Amplicheck®R7847Bc,e 0.8 or 3 Gas Rectifying
Flame Rod
Holdersh
C7004,
C7007,
C7011,
Complete
Assemblies:
C7008,
C7009, Q179
Dynamic
Amplicheck R7847Bc,e 3 Gas, oil, coal Ultraviolet
(Purple
Peeper)
C7012A, C
Dynamic
Self-check R7847Cg3 Gas, oil, coal Ultraviolet
(Purple
Peeper)
C7012E, F
Infrared Red/White No R7852A 3 Gas, oil, coal Infrared C7915
Dynamic
Amplicheck
R7852B 3 Gas, oil, coal Infrared C7915
Ultraviolet Purple No R7849A 0.8 or 3 Gas, oil Ultraviolet
(Minipeeper)
C7027,
C7035,
C7044d
Dynamic
Amplicheck R7849Bd0.8 or 3 Gas, oil Ultraviolet
(Minipeeper)
C7027,
C7035,
C7044d
Dynamic
Self-Check R7861Ab0.8 or 3 Gas, oil, coal Ultraviolet C7061
Blue Dynamic
Self-Check
R7886 3 Gas, oil, coal Ultraviolet
(Adjustable
sensitivity)
C7076
Optical White Dynamic
Amplicheck
R7851B 0.8 or 3 Gas, oil, coal Optical (UV,
Visible Light)
C7927,
C7962
Dynamic
Self-Check R7851Cb3 Gas, oil, coal Optical (UV
only)
C7961
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 6
a Flame Failure Response Time (FFRT) depends on selection of amplifier.
b Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during
burner operation and shuts down burner if detection system fails.
c Circuitry tests flame signal amplifier 12 times a minute during burner operation and shuts down burner if amplifier fails.
d Use C7027, C7035 and C7044 Flame Detectors only on burners that cycle on-off at least once every twenty-four hours.
Use C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet
flame detection system for appliances with burners that remain on continuously for twenty-four hours or longer.
e R7847A,B Amplifiers with 0.8 second FFRT should NOT be used with C7012A,C Solid State Ultraviolet Detectors.
g R7847C Series 4 or greater, check flame detector system when flame reaches 1.5 Vdc or at 4.5 seconds, whichever
occurs first.
NOTE: R7847C Series 4 or greater, pulse the shutter when signal of 1.5 Vdc is sensed. Display readings of 0.7 to 2.4 Vdc
are common.
h Order flame rod separately; see flame detector Instructions for holder.
Fig. 2. Rectification detectors.
Fig. 3. Rectification detectors.
THREADED
MOUNTING
HOLES (2)
(10-32 UNF)
1 (25)
FLAME ROD
TARGET
CERAMIC
INSULATORS
IGNITION
ELECTRODE
(Q179C ONLY)
BRACKET
M1983B
3-1/8
(79)
1-21/32
(42)
1-13/32
(36)
3/8 (10)
1/2 (13)
1-1/16
(27)
25/32
(20)
25/32
(20)
2-25/32
(62)
3/32 (2) 11/16
(18)
17/32
(14)
MOUNTING FLANGE
1/2- 14 NPSM
LEADWIRES FACEPLATE
3/4-14 NPT
M1962D
3-3/4
(95)
7-7/32
(183)
5-1/8 (130)
3-7/16
(87)
5-1/4 (133)
C7012A,C,E,F, C7061
RM7888A 7800 SERIES RELAY MODULE
732-00214—01
Fig. 4. Infrared detector.
Fig. 5. Ultraviolet detectors (minipeepers).
Fig. 6. Ultraviolet detectors (minipeepers).
APERTURE
BUSHING WITH
MAGNIFYING LENS
COLLAR, 3/4-14 NPSM
INTERNAL THREADS
3/4-14
NPSM 3/4-14 NPSM
INTERNAL
THREADS
HEAT BLOCKCELL MOUNT
M1982C
2-3/4
(70)
1-1/4
(32)
1-5/8 (41)
1-1/16 (27)
1-1/4
(32)
C7915
COLLAR WITH 1/2-14 NPSM
INTERNAL THREADS
4 (102) 8 FOOT (2.44 METER)
LEADWIRES (2)
M1943G
C7027A1064 HAS 24 FOOT (7.32 METER) LEADWIRES. C7027A1114 HAS
44 IN. (1.118 M) LEADWIRES WITH 22 IN. (558 MM) FLEXIBLE CONDUIT.
1
2
2
3-1/2 (89)
1-1/16
(27)
1
MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL
THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.
1/2-14 NPSM
INTERNAL THREADS
2
2 (51)
COLLAR WITH
1 - 11-1/2 NPSM
INTERNAL
THREADS 1
1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL MOUNTING THREADS.
DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL MOUNTING THREADS.
C7035A1056 HAS 12 FOOT (3.66 METER) LEADWIRES.
2
3
INSERTION DEPTH
6 FOOT
[1.83 METER]
LEADWIRES (2) 3
M1945E
2-5/8 (67)
1-1/2
(38)
31/32
(25)
4-1/8 (105)
1-3/16
(30)
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 8
Fig. 7. Ultraviolet detectors (minipeepers).
Fig. 8. Ultraviolet detectors (minipeepers).
6 FOOT
[1.83 METER]
LEAD
WIRES (2)
3-5/8 (92)
1/2
(13)
1-27/64
(36)
3/8
(10)
7/8
(22)
9/16
(14)
M1944D
MOUNTING
BRACKET
4
(102)
4 (102)
3/8 INCH NPT
1 INCH NPT
7/8 (22) OPENING
FOR 1/2-INCH CONDUIT
ALLOW 9 INCHES (228 MILLIMETERS)
CLEARANCE TO SWING OUT THE DETECTOR
FOR LENS CLEANING OR SERVICING.
1
M5083C
1-1/16 (27)
2-1/4
(57)
2-1/4
(57)
4-27/32 (123)
1-13/32 (188)
10-9/32 (261)
2-5/16
(58)
29/32 (23)
3/4 (19)
1-19/32
(41)
2-11/16
(68)
7-5/8 (194)
C7076A
RM7888A 7800 SERIES RELAY MODULE
932-00214—01
Table 5. Sequence Timing for Operation.
* STANDBY and RUN can be an infinite time period.
** PURGE will be determined by the system master controller.
*** RM7888A1001 and A1019 are 4 seconds; RM7888A1027 is 10 seconds.
PRINCIPAL TECHNICAL
FEATURES
The RM7888A provides customary flame safeguard
functions while providing significant advancements in the
areas of safety, annunciation and system diagnostics.
Safety Shutdown (Lockout) Occurs
if:
1. INITIATE Period
a. Configuration jumper was changed (after 200
hours).
b. AC line power errors, see Operation section.
c. Four minute INITIATE period is exceeded.
2. STANDBY Period
a. Flame signal is present after 240 seconds.
b. Pilot valve/1st stage main valve terminal is ener-
gized.
c. Main valve terminal is energized.
d. Internal system fault.
e. Flame detected during the last two seconds.
f. Limits Complete is not energized after 120 sec-
onds.
g. Hold @Low Fire Switch is not energized after
eight minutes of hold.
h. Flame Proven terminal energized.
i. Ignition terminal energized.
j. Configuration jumpers select is illegal (during
last two seconds).
3. PILOT FLAME ESTABLISHING Period (PFEP) (Pilot
Configuration)
a. Pilot/1st stage main valve terminal is not ener-
gized.
b. No flame is present at end of PFEP.
c. Internal system fault.
d. Main valve terminal is energized.
e. Limits Complete is not energized.
f. @Low Fire is not energized.
g. Ignition terminal is not energized for the first ten
seconds of PFEP.
h. Ignition terminal is energized after the first ten
seconds of PFEP.
i. Flame Proven terminal is energized for the first
ten seconds of PFEP.
j. Flame Proven terminal is not energized at the
end of PFEP.
k. Special Function 2 is not energized after eight
minutes (Pilot Configuration).
4. MAIN FLAME ESTABLISHING Period.
a. Pilot is not energized.
b. Pilot/1st stage main valve terminal is not ener-
gized.
c. Main valve terminal is not energized.
d. No flame present.
e. Internal system fault.
f. @Low Fire switch is not energized.
g. Ignition terminal is energized.
h. Flame Proven is not energized.
i. Limits Complete is not energized.
j. Special Function 2 is not energized.
k. Special Function 3 is not energized.
5. RUN Period
a. No flame present.
b. Flame Proven is not energized.
c. Internal system fault.
d. Ignition terminal is energized.
e. Pilot terminal is energized (Pilot configuration).
f. Pilot terminal/main valve first stage is not ener-
gized (DSI configuration).
g. Limits Complete is not energized.
h. Main valve is not energized.
6. Anytime the configuration jumpers are changed
while the RM7888A is powered.
7. PILOT RELIGHT
a. Limits Complete is de-energized.
b. Special Function 2 is not energized.
c. Special Function 3 is not energized.
d. Ignition, pilot, or main is not energized.
e. Low Fire is not energized.
f. Flame failure.
g. Ignition terminal not energized.
h. Flame Proven is not energized.
8. WAIT FOR LOW OFF FOR 5 SECONDS
a. Limits Complete is not energized.
b. Special Function 2 is not energized.
c. Flame failure.
d. Ignition energized.
e. Main energized.
f. Flame Proven not energized.
g. Pilot not energized.
9. DRIVE TO LOW
RM7888A
Sequence Initiate Standby Purge
Pilot Flame
Establishing Period
(PFEP)
Main Flame
Establishing
Period (MFEP) Pilot Relight Run
Pilot: PV
Return
10 seconds * ** 10 seconds 10 seconds 5 sec to
infinity
*
Pilot: MV Lo
Fire
10 seconds * ** 10 seconds 15 seconds — *
DSI Normal 10 seconds * ** *** — — *
DSI High/Low
Stepfire
10 seconds * ** *** — — *
DSI On/Off
Stepfire
10 seconds * ** *** — — *
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 10
a. Limits Complete is not energized.
b. Special Function 2 is not energized
c. Flame failure.
d. Ignition energized.
e. Main energized.
f. Flame Proven is not energized.
SAFTEY PROVISONS
Interal Hardware Status Monitoring
The RM7888A analyzes the integrity of the configuration
jumper and internal hardware. The POWER LED blinks
every four seconds to signify an internal hardware check.
Closed Loop Logic Test
The test verifies the integrity of all safety critical loads
(terminals 8, 9, 10 and 21). If the loads are not energized
properly, for example, the main valve terminal is powered
during purge, the RM7888A will lockout on a safety
shutdown. The RM7888A must react to input changes but
avoid the occurrence of nuisance shutdown events. Signal
conditioning is applied to line voltage inputs to verify
proper op-eration in the presence of normal electrical line
noise such as transient high voltage spikes or short
periods of line dropout. Signal conditioning is tolerant of
synchronous noise (line noise events that occur at the
same time during each line cycle).
Dynamic Flame Amplifier and
Shutter Check
Self-checking circuitry tests all electronic components in
the flame detection system and amplifier 12 times per
minute and shuts down the RM7888A if the detection
system fails.
Dynamic Amplifiercheck™
Dynamic Amplicheck™ circuitry tests the flame signal
amplifier during burner operation and shuts down
RM7888A if the flame amplifier fails.
Dynamic Input Check
All system input circuits are examined to make sure that
the RM7888A is capable of recognizing the true status of
external controls, limits and interlocks. If any input fails
this test, a safety shutdown occurs and the fault is
annunciated.
Dynamic Safety Relay Test
Checks the ability of the dynamic safety relay contacts to
open and close. Verifies that the safety critical loads
(terminals 8, 9, 10 and 21) can be de-energized, as
required, by the Dynamic Self-Check logic.
Dynamic Self-Check Safety Circuit
The microcomputer tests itself and related hardware, and
at the same time, the safety relay system tests the
microcomputer operation. If a microcomputer or safety
relay failure occurs and does not allow proper execution of
the self-check routine, safety shutdown occurs and all
safety critical loads will be de-energized.
Expanded Safe-Start Check
The conventional safe-start check, which prevents burner
start-up if flame is indicated at start-up, is expanded to
include a flame signal check during STANDBY, a safety
critical load check, a Limits Complete check, and an @Low
Fire check.
Off Cycle (Standby) Flame Signal
Check
The flame detection subsystem (flame detector and
amplifier) is monitored during STANDBY. If a flame
simulating condition or an actual flame exists for 40
seconds in STANDBY, a safety shutdown occurs and
startup is prevented. If the flame signal exists at any time
after 40 seconds during STANDBY, a safety shutdown
occurs and is annunciated.
• A shutter-check amplifier and self-checking detector
are energized continuously during STANDBY and the
last two seconds of STANDBY. If a flame exists, a safety
shutdown will occur.
• An Amplicheck™ Amplifier is energized continually
through STANDBY to detect any possibility of a
runaway detector or a flame. If either situation
happens, a safety shutdown will occur.
• A standard amplifier is energized continually through
STANDBY to detect any possibility of a runaway
detector or a flame. If either situation happens, a safety
shutdown will occur.
Tamper Resistant Timing Logic
Safety and logic timings are inaccessible and cannot be
altered or defeated.
Alarm Operation
This output will supply power to the system master and/ or
an external alarm indicator such as a bell or buzzer. The
alarm is turned on anytime a lockout has occurred and the
lockout condition has not been cleared. The alarm output
is also turned on when the reset button is pressed and
held for more than four seconds. The status of this output
is not monitored by the relay module.
First-Out Annuciation and Self-
Diagnostics
Sequence Status Lights (LEDs) provide positive visual
indication of the program sequence: POWER, PILOT,
FLAME, MAIN and ALARM. The green POWER LED blinks
every four seconds, signifying that the RM7888A
hardware is running correctly.
Optional Multi-function Keyboard Display Module shows
elapsed time during PILOT IGNITION and MAIN IGNITION.
As an additional troubleshooting aid, it provides RM7888A
SAFETY PROVISIONS sequence timing, diagnostic
information, and historical information when a safety
shutdown or hold or normal operation occurs.
First-out Annunciation reports the cause of a safety
shutdown or identifies the cause of a failure to start or
continue the burner control sequence with an English text
and numbered code via the Keyboard Display Module. It
monitors all field input circuits, including the flame signal
RM7888A 7800 SERIES RELAY MODULE
11 32-00214—01
amplifier and output circuits. The system distinguishes
modes of failure and detects and annunciates difficult-to-
find intermittent failures.
Self-diagnostics add to the First-out Annunciation by
allowing the RM7888A to distinguish between field
(external device) and internal (system related) problems.
Faults associated within the flame detection subsystem or
the RM7888A are isolated and reported by the optional
Keyboard Display Module. See Hold and Fault Message
Summary in the Checkout and Test, form 65-0229.
Interlock Requirements
The following interlock inputs are provided.
Limits Complete (Terminal 7)
This input provides an indication of the status of an
interlock string. If this input is energized, it is permissible
to operate through a burner sequence. The burner
sequence does not leave the Standby state if the Limits
Complete signal is de-energized. If this input becomes de-
energized after leaving the Standby state, one or more
interlocks are open and the burner sequence is either
recycled or a lockout occurs as defined for the particular
burner state.
@Low Fire (Terminal 18)
This input will provide an indication of the low firing rate
position. If this input is energized, the motor position is
assumed by the relay module to be at the Low Fire position;
otherwise, the motor position cannot be determined if this
input is de-energized.
This signal is readable in any burner operating state
without regard to the status of the special function signals
or the Limits Complete signal. The RM7888 does not
perform a test to assure that the Low Fire input signal
becomes energized when the High Fire motor control is
commanded. For example, the RM7888 will not detect a
Low Fire input that is jumpered or continuously energized
without regard to the actual motor position.
The High Fire position is not confirmed by a separate high
fire input at the RM7888. The system master control is
responsible for the High Fire proving and purging of the
combustion unit.
INSTALLATION
WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY, OR
DEATH.
To prevent possible hazardous burner operation,
perform verification of safety requirements each
time a control is installed on a burner.
When Installing This Product...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazard-
ous condition.
2. Check the ratings given in the instructions and
marked on the product to make sure the product is
suitable for your application.
3. Installer must be a trained, experienced, flame safe-
guard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
CAUTION
To prevent electrical shock and equipment
damage, disconnect the power supply before
beginning installation. More than one power
supply disconnect may be involved.
1. To prevent electrical shock and equipment damage,
disconnect the power supply before beginning
installation. More than one power supply disconnect
may be involved.
2. Wiring connections for the RM7888A are unique;
therefore, refer to Fig. 11 or the correct specifica-
tions for proper subbase wiring.
3. Wiring must comply with all applicable codes, ordi-
nances and regulations.
4. Wiring, where required, must comply with NEC Class
1 (Line Voltage) wiring.
5. Loads connected to the RM7888A must not exceed
those listed on the RM7888A label or the specifica-
tions (see Table 1).
6. Limits and interlocks must be rated to carry and
break current simultaneously to the ignition trans-
former, pilot valve, and main fuel valve(s).
7. All external timers must be listed or component rec-
ognized by authorities who have jurisdiction for the
specific application.
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 12
IMPORTANT:
1. For on-off gas-fired systems, some authorities
who have jurisdiction prohibit the wiring of any
limit or operating contacts in series between the
flame safeguard control and the main fuel valve(s).
2. Two detectors can be connected in parallel, with
the exception of the Solid State detectors (C7915,
C7927, C7962 and C7961).
3. This equipment generates, uses and can radiate
radio frequency energy, and if not installed and
used in accordance with the instructions, may
cause interference to radio communications. It
has been tested and found to comply with the lim-
its for a Class A computing device of part 15 of
FCC rules, which are designed to provide reason-
able protection against such interference when
operated in a commercial environment. Operation
of this equipment in a residential area may cause
interference, in which case the users, at their own
expense, may be required to take whatever mea-
sures are required to correct this interference.
4. This digital apparatus does not exceed the Class A
limits for radio noise of digital apparatus set out in
the Radio Interference Regulations of the Cana-
dian Department of Communications.
5. RM7888A cannot be connected in parallel without
isolation circuits to isolate input and output cir-
cuits.
Humidity
Install the RM7888A where the relative humidity never
reaches the saturation point. The RM7888A is designed to
operate in a continuous, noncondensing moisture
environment with a maximum 85 percent relative
humidity. Condensing moisture can cause a shutdown.
Vibration
Do not install RM7888A where it could be subjected to
vibration in excess of 0.5G continuous maximum
vibration.
Weather
The RM7888A is not designed to be weather tight. If
installed outdoors, the RM7888A must be protected by an
approved weather-tight enclosure.
Relay Module and Subbase
Compatiblity
NOTE: There are several different subbase models that
can be purchased. It is important to note which
subbase is compatible with the relay module
when purchasing new, repair or replacement
parts.
Series 1000 Relay Modules
All relay product codes that start with a 1 (example:
RM7840G1014/U) can be used with existing subbase
Q7800A1003/U and Q7800A1005/U.
Series 2000 Relay Modules
All relay product codes that start with a 2 (example:
RM7840G2014/U) must be used with subbase
Q7800A2003/U and Q7800A2005/U.
Subbase Compatibility
Any Relay Module in the 1000 Series with a Software
Revision level number starting with a "5" or greater will be
compatible with all subbase models both installed and
newly purchased. This includes (Q7800A1005/U,
Q7800B1003/U), and the 2000 Series subbases
(Q7800A2005/U, Q7800B2003/U).
See Fig. 1 for Software Revision Level number location on
the label (located on the rear of the relay module).
Any relay module in the new 2000 series will only be able
to be installed on subbase Q7800A2005/U,
Q7800B2003/U and will not be backward compatible with
any Q7800A1003/U and Q7800A1005/U subbases
already installed in the field.
Fig. 9. Software revision location.
IMPORTANT
Make sure to check the relay model number and
the software revision level on the relay.
• If you attempt to place a 2000 series relay on a
non-compatible 1000 series subbase, you will
receive an error code of 101. This indicates that
you must a) change out the subbase to a
Q7800A2003/U or Q7800A2005/U or b) choose a
compatible 1000 series relay module.
Mounting Wiring Subbase
NOTE: For installation dimensions, see Fig. 1.
1. Mount the subbase in any position except horizon-
tally with the bifurcated contacts pointing down. The
standard vertical position is recommended. Any
other position decreases the maximum ambient
temperature rating.
2. Select a location on a wall, burner or in an electrical
panel. The Q7800 can be mounted directly in the
control cabinet. Be sure to allow adequate clearance
for servicing, installation, access and removal of
RM7888A, dust cover, flame amplifier, flame ampli-
fier signal voltage probes, electrical signal voltage
probes and electrical field connections.
3. For surface mounting, use the back of the subbase
as a template to mark the four screw locations. Drill
the pilot holes.
RM7888A 7800 SERIES RELAY MODULE
13 32-00214—01
4. Mount the subbase securely using four No. 6 screws.
NOTE: You might receive an error code 101 (via KDM) if
one of the following conditions exist:
a. The screws securing the relay to the subbase are
not tight enough, re-tighten to insure there is no
gap between the relay and the subbase.
b. If you attempt to place a 2000 series relay on a
non-compatible 1000 series subbase, this indi-
cates that you must:
• Change out the subbase to a Q7800A2003/U
or Q7800A2005/U
• Choose a compatible 1000 series relay
modulebase to a Q7800A2003/U or
Q7800A2005/U
WIRING
1.
a. For the internal block diagram of the RM7888A,
see Fig. 10.
b. For proper subbase wiring, refer to Fig. 11.
c. For proper remote wiring of the Keyboard Display
Module; refer to the Specifications for the Key-
board Display Module (65-0090), or Extension
Cable Assembly (65-0131).
2. Disconnect the power supply from the main discon-
nect before beginning installation to prevent electri-
cal shock and equipment damage. More than one
disconnect may be involved.
3. All wiring must comply with all appropriate electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC Class 1 wiring.
Fig. 10. RM7888A internal block diagram.
CONFIGURATION
JUMPERS
MICROCOMPUTER
RESET
PUSHBUTTON
STATUS LEDs
SAFETY RELAY
CIRCUIT
POWER SUPPLY
OPTIONAL
KEYBOARD
DISPLAY MODULE
PLUG-IN
FLAME
AMPLIFIER
RELAY
DRIVE
CIRCUIT
CONTROL
POWER
TEST
JACK
L2
REMOTE
RESET
DDL
DDL
COMMUNICATIONS
INDICATES FEEDBACK SENSING
OF RELAY CONTACT
AND LINE VOLT INPUTS
FIELD WIRING
INTERNAL WIRING
IGNITION
AIRVALVE
MAIN VALVE
1K
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
1K1 5K1
120 Vac
FLAME SIGNAL
TEST
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
120 VAC INPUT FROM SYSTEM MASTER CONTROLLER REFER TO
TABLE 1 AND FIGURE 8.
RS485
1
2
3
L1 (HOT) L2
4
6
7
6K1
4K1
2K2
5
3
10
8
9
7K
5K
4K
3K
2K
F
G
22
1
FLAME
PROVEN
7K1
21
1
2
2
2
2
2
M9496D
LIMITS COMPLETE
ALARM
PILOT
SPECIAL FUNCTION 1
17
18 LOW FIRE
SWITCH
SPECIAL
FUNCTION 2
SPECIAL
FUNCTION 3
SPECIAL
FUNCTION 4
19
20
8K1
HIGH FIRE 12
COMMON 13
MODULATE
15
LOW FIRE 14
9K1
8K2
9K2
5
2K2
3K1
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 14
Fig. 11. RM7888A wiring diagram.
4. Recommended wire size and type:
a. Use 14, 16, or 18 AWG copper conductor
(TTW60C or THW75C or THHN90C) 600 volt
insulation wire for all line voltage terminals. For
high temperature installations, use wire selected
for a temperature rating above the maximum
operating temperature. All leadwires must be
moisture resistant.
b. Keyboard Display Module—For communications
purposes, use an unshielded 3-wire twisted
cable if the leadwire run and noise conditions
permit; however, some installations may need up
to five wires; three for communications and two
for remote reset (either in a single cable or sepa-
rate cables for communications or remote reset)
or use Belden 8771 shielded cable or equivalent.
The Keyboard Display Module, DATA CONTROL-
BUS MODULE™ (for remote mounting or com-
munications) or Modbus Module must be wired
in a daisy-chain configuration, 1(a)-1(a), 2(b)-
2(b), 3(c)- 3(c)). The order of interconnection of
all the devices is not important. Be aware that
modules on the closest and farthest end of the
daisy chain configuration require a 120-ohm
(1/4 watt minimum) resistor termination across
terminals 1 and 2 of the electrical connectors for
connections over 100 feet [30 meters].
c. DATA CONTROLBUS or MODBUS MODULE™—
For communications purposes, use an
unshielded 3-wire twisted cable if the leadwire
run and noise conditions permit; however, some
installations may need up to five wires; three for
communications and two for remote rest (either
in a single cable or separate cables for communi-
cations or remote reset) or use Belden 8771
shielded cable or equivalent. The Keyboard Dis-
play Module, DATA CONTROLBUS MODULE™
(for remote mounting or communications) or
Modbus Module must be wired in a daisy-chain
configuration, 1(a)-1(a), 2(b)-2(b),3(c)-3(c)). The
order of interconnection of all the devices is not
important. Be aware that modules on the closest
and farthest end of the daisy chain configuration
require a 120-ohm (1/4 watt minimum) resistor
termination across terminals 1 and 2 of the elec-
trical connectors for connections over 100 feet
[30 meters].
M9495A
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
MASTER
SWITCH
LIMITS
SPECIAL
FUNCTION 1
SPECIAL
FUNCTION 2
SPECIAL
FUNCTION 3
SPECIAL
FUNCTION 4
FLAME
INDICATION
MAIN FUEL
VALVE(S)
120V ALARM
PILOT
FLAME
DETECTOR
120V POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
L1
(HOT)
L2
1
L2
L1
L2
1
Q7800 SUBBASE HIGH
FIRE
COMMON
LOW
FIRE
MODULATE
B
R
W
SERIES 90
FIRING
RATE
MOTOR
B
R
W
SERIES 90
CONTROLLER
LOW FIRE
SWITCH
IGNITION
AIR VALVE
EXTERNAL
CONTROLLER
FOR DIRECT SPARK
IGNITION (OIL OR GAS)
IGNITION
2ND STAGE
FUEL VALVE
1ST STAGE
FUEL VALVE 8
9
10
RM7888A 7800 SERIES RELAY MODULE
15 32-00214—01
d. Remote Reset—Use 22 AWG or greater twisted
pair wire, insulated for low voltage.
5. Recommended grounding practices:
a. Use earth ground to provide a connection
between the subbase and the control panel or
the equipment. The earth ground wire must be
capable of conducting the current to blow the
15A fast blow fuse (or breaker) in the event of an
internal short circuit. The RM7888A needs a low
impedance ground connection to the equipment
frame which, in turn, needs a low impedance
connection to earth ground. For a ground path to
be low impedance at RF frequencies, the connec-
tion must be made with minimum length con-
ductors that have a maximum surface area. Wide
straps or brackets are preferred rather than lead-
wires. Make sure that mechanically tightened
joints along the ground path, such as pipe or
conduit threads or surfaces held together with
fasteners, are free of nonconductive coatings
and are protected against mating surface corro-
sion.
b. Keyboard Display Module, DATA CONTROLBUS
MODULE™ or Modbus Module—The shield, if
used, should be connected to the signal ground
terminal 3(c) provided as part of the 7800
SERIES device ControlBus connection. The
shield should be connected at both ends to
ground.
c. RM7888A—Each RM7888A will have an earth
ground terminal that must be grounded to the
metal control panel with wire as short as practi-
cal. Each ground wire must be capable of carry-
ing a fault current equal to the rating of the
protective fuse 15A fast blow. A 14 AWG copper
conductor is adequate, but wide straps or brack-
ets are preferred to leadwires.
6. Recommended wire routing:
a. Flame detector leadwires:
(1) Do not run high voltage ignition transformer
wires in the same conduit with flame detec-
tion wiring.
(2) Do not route scanner wires in a conduit with
line voltage circuits.
(3) Enclose scanner wires without armor cable in
metal cable or conduit.
(4) Follow directions given in flame detector
instructions.
b. DATA CONTROLBUS MODULE™ or Modbus
Module:
(1) Do not run high voltage ignition transformer
wires in the same conduit or in close proxim-
ity to the MODULE wiring.
(2) Do not route MODULE wires in conduit with
line voltage circuits.
c. Keyboard Display Module:
(1) Because the VFD is powered from a low volt-
age, energy limited source, mount it outside a
control panel, without using special wiring
procedures, if it is protected from mechanical
damage.
d. Remote Reset:
(1) Do not run high voltage ignition transformer
wires in the same conduit with the Remote
Reset wiring.
(2) Do not route Remote Reset wires in the same
conduit with line voltage circuits.
7. Maximum wire lengths:
a. For the flame detector leadwires, the maximum
flame sensor leadwire length is limited by the
flame signal strength.
b. For the Remote Reset leadwires, the maximum
length of wire is 1000 feet to a Remote Reset
pushbutton.
c. For the DATA CONTROLBUS or MODBUS MOD-
ULE™, the maximum cable length depends on
the number of system modules connected, the
noise conditions and the cable used. The maxi-
mum length of all interconnecting wire is 1000
feet [305 meters].
8. Make sure loads do not exceed the terminal ratings.
Refer to the label on the RM7888A or to the ratings
in the specifications; see Table 1.
9. Check the power supply circuit. The voltage and fre-
quency tolerance must match those of the
RM7888A. A separate power supply circuit may be
required for the RM7888A with the required discon-
nect means and overload protection added.
10. Check all wiring circuits and complete the Static
Checkout before installing the RM7888A on the sub-
base: see Table 10.
11. Install all electrical connectors.
12. Restore power to the panel.
ASSEMBLY
Mounting the RM7888A
NOTE: For installation dimensions, see Figs. 1
Relay Module Mounting
(Figs. 12 and 13)
1. Mount RM7888A vertically, see Figs. 12 or 13, or
mount horizontally with the knife blade terminals
pointing downward. When mounted on the Q7800A,
the RM7888A must be in an electrical enclosure.
2. Select the location in the electrical enclosure. Be
sure to allow adequate clearance for servicing,
installation and removal of the RM7888A, Keyboard
Display Module, flame amplifier, flame amplifier sig-
nal voltage probes, electrical signal voltage probes
and electrical connections.
a. Allow an additional two inches below the
RM7888A for the flame amplifier mounting.
b. Allow an optional three-inch minimum to both
sides of the RM7888A for electrical signal volt-
age probes.
3. Make sure no subbase wiring is projecting beyond
the terminal blocks. Tuck in wiring against the back
of the subbase so it does not interfere with the knife
blade terminals or bifurcated contacts.
IMPORTANT:
The RM7888A must be installed with a plug-in
motion rather than a hinge action.
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 16
Fig. 12. Electrical panel installation.
Fig. 13. Wall or burner installation.
4. Mount the RM7888A by aligning the four L-shaped
corner guides and knife blade terminals with the
bifurcated contacts on the wiring subbase and
securely tightening the two screws without deform-
ing the plastic.
Mounting the Keyboard Display
Module (Fig. 14)
1. Align the two interlocking ears of the Keyboard Dis-
play Module with the two mating slots on the
RM7888A.
2. Insert the two interlocking ears into the two mating
slots and, with a hinge action, push on the lower cor-
ners of the Keyboard Display Module to secure it to
the RM7888A.
3. Make sure the Keyboard Display Module is firmly in
place.
Fig. 14. Keyboard Display Module mounting.
Mounting the Data Controlbus
Module™, Modbus Module or the
Extension Cable Assembly (Figs. 15
and 16)
1. Align the two interlocking ears with the two mating
slots on the RM7888A.
2. Insert the two interlocking ears into the two mating
slots and push on the lower corners of the DATA
CONTROLBUS MODULE™, Modbus module or
Extension Cable Assembly to secure it to the
RM7888A.
3. Make sure the modules are is firmly in place.
Fig. 15. DATA CONTROLBUS MODULE™ mounting.
RM7888A 7800 SERIES RELAY MODULE
17 32-00214—01
Fig. 16. Extension Cable Assembly mounting.
Remote Mounting the Keyboard
Display Module (Fig. 17)
1. The Keyboard Display Module can be mounted
either on the face of a panel door or other remote
locations.
NOTE: A DATA CONTROLBUS MODULE™ or an Exten-
sion Cable Assembly is required to connect
RM7888A to a remote Keyboard Display Module.
2. When mounting the Keyboard Display Module on
the face of the door panel, closely follow these
instructions:
a. Select the location on the door panel for flush
mounting. Pay attention to the insertion dimen-
sion of the two Keyboard Display Module screws,
two interlocking ears and the two plug-in con-
nectors to allow for sufficient clearance (1/4 in.
[6 mm] minimum) inward from the surface of the
door panel.
b. Mark the two screw locations, two interlocking
ear locations and the two plug-in connector
locations. Drill the pilot holes for the mounting
screws. Provide for two holes on the door panel
for the interlocking ears and two holes for the
plug-in connectors.
c. Mount the Keyboard Display Module on the door
using two no. 4 screws.
3. When mounting the Keyboard Display Module on a
wall or remote location, use part number 203765,
Remote Mounting Bracket.
a. Using the Remote Mounting Bracket as a tem-
plate, mark the four screw locations and drill the
pilot holes.
b. Mount the Remote Mounting Bracket using four
no. 6 screws.
c. Mount the Keyboard Display Module by aligning
the two interlocking ears with the two mating
slots on the Remote Mounting Bracket.
d. Insert the two interlocking ears into the two mat-
ing slots. Push on lower corners of the Keyboard
Display Module to secure it to the Remote
Mounting Bracket. e. Make sure the Keyboard
Display Module is firmly in place.
Installing the Plug-in Flame Signal
Amplifier
1. Disconnect the power supply before beginning the
installation to prevent electrical shock and equip-
ment damage. More than one disconnect may be
involved.
2. Align the amplifier circuit board edge connector with
the keyed receptacle on the RM7888A. Make sure
the amplifier nameplate faces away from the Relay
Module.
3. Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the
amplifier toward the RM7888A retaining clasp.
4. Make sure the amplifier is firmly in place.
5. Perform all required checkout tests.
Fig. 17. Remote mounting of Keyboard Display Module.
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 18
Fig. 18. Flame signal amplifier mounting.
Installing the Flame Detector (Fig.
19)
NOTE: Table 4 lists the flame detection systems avail-
able for use with the RM7888A. Make sure the
correct combination of amplifier and flame detec-
tor(s) is used.
Proper flame detector installation is the basis of a safe
and reliable flame safeguard installation. Refer to the
instructions packed with the flame detector and the
equipment manufacturer instructions.
Keep the flame signal leadwires as short as possible from
the flame detector to the wiring subbase. Capacitance
increases with leadwire length, decreasing the signal
strength. The maximum permissible leadwire length
depends on the type of flame detector, leadwire and
conduit. The ultimate limiting factor in the flame signal is
the flame detector leadwire.
Fig. 19. Flame detector wiring.
BLUE
YELLOW
WHITE
WHITE
BLACK
BLACK
F
G
22
L2
L1
L2
M1969C
BLUE
WHITE
F
G
BLUE
WHITE
F
G
INFRARED (C7915)
ULTRAVIOLET (C7027/C7035/C7044)
SOLID STATE SELF-CHECKING
ULTRAVIOLET (C7012E,F)
BLUE
YELLOW
BLACK
BLACK
F
G
L1
L2
SOLID STATE
ULTRAVIOLET (C7012A,C)
1
22
F G
4
5
3
L2
C7076A,D ULTRAVIOLET DETECTOR
522
6
SHUTTER
G
SHUTTER
F
1
8
2
7
7800 SERIES
L1
L2
3a 3b
REMOTE
SENSOR
2b
2a
EARTH
GROUND
C7076A
OR
C7076D
TERMINAL
BLOCK
L2 (COMMON)
L1 (HOT)
G
F
X
X
FLAME ROD
G
F
X
X
PHOTOCELL
1FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
2
RM7888A 7800 SERIES RELAY MODULE
19 32-00214—01
OPERATION
WARNING
The user of the RM7888A is responsible for
providing an effective purge that meets the
approval of the authority having jurisdiction for a
particular installation. Failure to provide an
effective purge can result in a fire or explosion
that can cause damage, serious injury or death.
Sequences of Operation
The RM7888A has five user selectable operating
sequences: Pilot—PV Return; Pilot—MV Lo Fire; Direct
Spark Ignition (DSI) Normal Operating Sequence; DSI
High/Low Stepfire Operating Sequence and DSI Off/On
Stepfire Operating Sequence. Each operating sequence
will be discussed in detail.
CAUTION
The user selects the appropriate control
sequence by clipping configuration jumpers.
Sequence selection must be done correctly.
Failure to select the sequence correctly can be
hazardous. Follow instructions in this
specification.
Selectable Site-Configurable
Jumpers
The RM7888A has five site-configurable jumper options
and three options that will result in a lockout, see Fig. 20
and Table 6. The site-configurable jumpers should be
clipped with side cutters and the resistor removed from
the Relay Module.
Fig. 20. Selectable site-configurable jumpers.
Table 6. Site-Configurable Jumper Options.
1 Each operating sequence is described individually in the Operation section of this specification. Read the appropriate
operating sequence section carefully before clipping jumpers. The sequence selection cannot be reversed.
Pilot Configuration Operating
Sequence
The Pilot Configuration Operating Sequence has two
distinct operating sequences that are entered from the
Standby/ Standby Purge states. The sequences are:
a. PV Return: allows the control to reestablish the
pilot and de-energize the main flame in response
to the system heating requirements.
b. MV Lo Fire: will not allow the pilot to be re-estab-
lished once RUN has been entered; the main
valve remains energized with Lo Fire being the
lowest firing rate allowed.
See Table 7 for the state names, the text that appears on
the S7800 Keyboard Display Module, and the purpose.
Jumper
RM7888A ActionJ1 J2 J3
Intact Intact Intact Default, selects the Pilot Configuration Burner
Sequence, including the Pilot Relight Function.(PV
Return)1
Intact Clipped Clipped Selects DSI Normal Burner Sequence.1
Clipped Intact Clipped Selects DSI High/Low Stepfire Burner Sequence.1
Clipped Clipped Intact Selects DSI Off/On Stepfire Burner Sequence.1
Intact Intact Clipped Selects Pilot Configuration Burner Sequence, but
excludes the Pilot Relight Function.(MV Lo Fire)1.
Intact Clipped Intact Illegal; will result in a lockout.
Clipped Intact Intact Illegal; will result in a lockout.
Clipped Clipped Clipped Illegal; will result in a lockout.
RM7888A 7800 SERIES RELAY MODULE
32-00214—01 20
Table 7. Pilot Configuration Operation Sequence States.
Pilot Configuration
State Name
S7800 Keyboard
Display Module
Displayed Text Purpose of State
Initiate (See below) The Initiate state allows the relay module to complete initialization after a
power-up or whenever a problem that would prevent normal operation (such
as an ac line problem), the Initiate state is entered.
Initiate INITIATE mm:ss Displayed during timed portion of the Initiate state.
Initiate INITIATE HOLD: AC
(AC Freq/Noise)
Displayed during Initiate state if the ac frequency is low or noise is present.
Initiate INITIATE HOLD: AC
(AC Line Dropout)
Displayed during Initiate state if the ac line power was lost.
Initiate INITIATE HOLD: AC
(AC Frequency)
Displayed during Initiate state if the ac frequency is high.
Initiate INITIATE HOLD: AC
(Low Line Voltage)
Displayed during Initiate state if the ac line voltage is low.
Off STANDBY Remaining idle until valid input(s) are received. All safety loads are
commanded off.
— STANDBY HOLD: F/G
(Flame Detected)
Displayed when a flame is detected.
— STANDBY HOLD: T7
(Lockout ILK)
Displayed when a call for operation is active and the Limits Complete signal
is off.
PURGE HOLD: T18
(Low Fire Switch)
Displayed when a call for operation is active and the Low Fire Switch signal
is off.
Purge PURGE 01:00 Purge at high fire. All safety loads are commanded off. Display indicates
Purge type 1 = Purge.
Control Cool PURGE 02:00 Purge at the motor position commanded by the modulating control. All
safety loads are commanded off. Display indicates Purge type 2 = Control
Cool.
Low Combustion Air
Only
PURGE 03:00 Purge at low fire. All safety loads are commanded off. Display indicates
Purge type 3 = Low Combustion Air Only.
Pilot Ignition PILOT IGN mm:ss Establish a pilot flame. Display shows state and elapsed time. At end of Pilot
Ignition timed state, timer will stop and display will show final time while a
hold exists.
Main Train Fuel On MAIN IGN 00:00 Allow for main valve operators to be placed into the normal operating
condition. Display shows state with zero elapsed time while waiting for a
hold condition(s).
Burner Fuel Valve
Open (Pilot Timeout)
MAIN IGN 00:ss Establish a main flame and drop the pilot flame. Display will show MFEP
state elapsed time.
Release to
Modulation
RUN Allow normal operation to take place where a modulating control provides
the motor position signal.
— RUN When special function input terminal 20 is off, relay module will command a
Low Fire motor position.
@Low 10 Sec RUN When the Low Fire input becomes energized for a continuous time period of
10 seconds, the sequence will leave the Release to Modulation state and
proceed to the Pilot Relight state (PV Return sequence only).
Pilot Relight PVHOLD IGN 00:ss Re-establish the pilot flame and drop the main flame. Display indicates
elapsed time in this timed state (PV Return sequence only).
Low Off 5 Sec. PVHOLD IGN 01:00 Wait for the Low Fire input signal to become de-energized for a continuous
period of five seconds and then proceed to the Main Train Fuel On state
after driving back to the Low Fire position. Display indicates that sequence
is in Pilot Hold State type 1 = Waiting for Low Off 5 Sec.
Drive to Low PVHOLD IGN 02:00 Commands the low fire motor position and waits until the Low Fire input
becomes energized before proceeding to the Main Train Fuel On state.
Display indicates that sequence is in Pilot Hold State type 2 = Waiting for
Low Fire On.
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Honeywell 7800 series Operating instructions

Honeywell
Brand
Honeywell
Model
7800 series
Type
Operating instructions
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